Design Electrical Power Connectors | Hello!

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Designing electrical power connectors involves determining parameters such as length and thickness based on required current ratings. The discussion focuses on connectors like tee-connectors and parallel groove connectors used in transmission lines and substations, with materials primarily being aluminum alloy. Test results are available for existing units, but guidance is sought for designing new sizes. A suggestion is made to calculate resistance for a first-level approximation to assess ohmic heating. The conversation emphasizes the need for precise formulas or guiding factors in connector design.
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Hello!

I am in design and manufacturing of electrical power connectors. I need to know if there is any precise formula to design a connector, i.e. given the required current rating, is there a particular formula that gives the parameters of the connector, like length and thickness??

All our connectors are made of Aluminium alloy. So resistivity, material density and Specific heat remain constant.

Looking forward for a help...
 
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hi!

these are power connectors, like tee-connectors, parallel grove connectors used in transmission lines and substations...
 
closepet said:
hi!

these are power connectors, like tee-connectors, parallel grove connectors used in transmission lines and substations...

Do you have test results for your units? Or are you trying to do theoretical calculations to back up what you have?
 
yeh we do have test results. But for newer sizes, we require some kind of a guiding factor for the design...
 
Can you not just calculate the simple resistance and then determine ohmic heating?

EDIT: At least, as a first level approximation?
 

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